Fabrics and like materials



y w. l. TAYLOR EI'A'L I 2,376,983

FABRICS AND LIKE MATERIALS FileciOct. 22 1943 W.I.TAYLOR :r-F- LEVE INVENTORS Patented May 29, 1945 FABRICS AND LIKE. MATERIALS William Ivan Taylor and James Frederick Levers, v Spondon, near Derby, England Application October 22, 1943, Serial No. 507,238 In Great Britain May 21, 1941 28 Claims.

This invention relates to the manufacture of fabrics and like materials, and to the manufacture of pile fabrics and analogous materials which are wind-proof or water-proof materials.

The present application is a continuation in part of our co-pending application S. No. 440,038, filed April 22, 1942.

We have found that a new effect may be obtained by subjecting pile fabrics, of which the pile comprises fiat filaments of a cellulose derivative, to the crinkling action of a boiling aqueous me dium. When treated in this way, the pile of such fabric is compacted and, if the treatment is applied while the fabrics are substantially free from tension, may assume a granulated appearance, which may resemble the appearance of animal pelts, e. g., lambs wool.

The filaments from which'the pile of fabrics to be treated according to the invention is made may be produced by any method which yields filamentsof a bone-shaped or othei' relatively flat cross-section. For example, suitable filaments having a basis of-cellulose acetate may be produced from spinning solutions in which the proportion of cellulose acetate is relatively low; thus a solution of about 21-22% of cellulose acetate fabrics having a-pile of fibres, the base of which is any other cellulose derivative or-like material which is susceptible to the crinkling action of hot aqueous media, for example to fabrics having a pile of cellulose aceto-propionate or aceto-butyrate fibres.

The length of the pile may be varied over a wide range, depending upon the purpose for which the fabric is being produced. For example, in'

producing velvet fabric for use in light-weight textiles. the pile length may be of the order of /8 /4 inch, while for rugs the pile length may be as much as 1 inch, or up to 1 or 1% inch, or even more; it is found that the treatment according to the invention may reduce the depth 0 the pile by approximately one half.

The backing of the fabric may comprise cotton or other natural textile material, ora synthetic textile material, e. g., a material having a basis of regenerated cellulose, formed, for example, by

of staple fibres to the backing fabric by sewing) whereby the bulky effect which would result when bundles of staple fibre are knotted on to a backing may be avoided. When shorter pile products are required, the fabric may-be produced by one of the more usual methods of producing pile fabrics, e. g., by weaving and subsequently cutting. I'he pile components of such fabrics may be made from continuous filament yarns, staplised yarns, formed, for example, by subjecting continuous filament yarns to abrasion, oryarns composed of a staple fibre of suitable length Whatever the type of yarn which is employed for making the pile components, the twist should be kept as low as possible consistent with satisfactory processing. I

Thetreatment of the pile fabrics may be carried out by immersing them in the bath of boiling aqueous medium for a period sufiicient to produce the desired degree of crinkle, preferably for a period of at least 2 hours, and advantageously for a period of 4 'hours or more, especially when no preliminary treatment designed to accelerate the crinkling action has been applied. An increased degree of crinkle may be secured in a. corresponding period of treatment by passing the boiling liquid through the fabric from the back This caustic soda treatment appears to result in a' slight superficial saponification of the pile fibres, and is particularly effective when the boiling bath contains Glaubers salts or other electrolyte. Such a caustic soda pretreatment leads to a somewhat delustred product. but it has been. Y

found that treatment of the fabric with dilute hydrochloric acid, e. g., 1.5-2.0 gins, per litre, be-

fore boiling substantially restores the original lustre withoutimpairing the crinkling effect.

When the pile fabrics are treated with boiling water alone for a period of 2 hours or more, be-

' sides the simple crinkling of the staple fibre, the

fibre becomes somewhat delustred. A good matt lustre is obtainable by boiling in a liquor having a pH value of about 11. Should it bedesired to delustre the materials fully, aproportion of soap,

e.'g., a proportion of 2% to 5 grams per litre, or

other wetting agent may be incorporated in the treatment medium, while, if it is desired to counteract the delustrlng tendency, salts or sugars, r and particularly Glauber's salts, may be added in. small proportions to the water, e. g., a solution containing 20 grams of Glaubers salts per litre maybe employed. 'By suitably modifying the As indicated above, if the treatment with the boiling aqueous medium-is carried out in the absence of tension, the pile face of the fabric about 4 hours or more. This granular effect depends for its degree upon the length of the pile, being'generally less noticeable with the shorter piles-.- The pile length is advantageously at least about inch. Pile lengths'of about /4--l inch, before treatment, yield products having the appearance of lambs woolon the skin.- The granulation is resistant to crushing or other distortion,

and remains in the material after washing or other treatments to which it may be subjected in normal use. If desired, the fabric maybe folded or-creasedfor. the pile face thereof may be imbossed, before the'boiling water treatment with I acquires a granulated or patterned appearance, particularly if the treatment is carried on for greasy handle, such as is usually associated with undressed sheepskin.

The production of windor water-proof materials according to the invention maybe achieved by impregnating the backing of the-pile fabric, preferably after the pile has been crinkled by the treatment with a boiling aqueous medium,;with a suitable hydrophobe, materiaL Rubber, applied for example as rubber latex, is an example of such a material, but we prefer to employ synthetic hydrophobe materials. Thus, according to the present invention the backing may be im-' pregnated with synthetic resins, among which may be mentioned the alkyd resins and derivof a diene and styrene, Or of a diene and isobutyleneysuitable dienes are, for example, l.3- butadiene, isoprene' and chloroprene. Another class of materials which may be employed according to the invention is that of-cellulose derivatives, and it has been found that when backfillirig with the same cellulose derivative as-that present in the pile of the treated fabric the operaton may frequently be carriedout without spec al precautions to protect the roots of the cellulose derivative pile during such treatment. Thecellulos'e derivative employe may be, for ex: ample, cellulose acetate, cellulose 'utyrate, cellulose aceto-butyrate, cellulose aceto-stearate, or other simple or mixed celluloseesterof an or.-

- ganic-acid, ora cellulose ether, e. g., ethyl cellu- I 'will'ilargely depend upon the nature of theagent,

a view to pre-disposing the pile to crinkle in a particular pattern.

-Fabrics may be treated locally according to theinvention for the production of fancy effects. For example, by suitable stencils the boiling water may be prevented from acting on selected areas of the'fabric, and the products willthen show areas q of crinkled pile with or without a modified lustre,-.

alternating with areas of uncrinkled pile having *the lustre or the original material.

- After treatment with the aqueous medium according to the invention, the fabrics may-be subiected to further treatments adapted to modify their appearance or other characteristics as may be desired; Thus, thy'mayfbe treated with a oxy-methyl chloride, and subsequently dried and baked at about 12o'"c. By such a treatment as that last-mentioned-long pile fabrics of whichthe pilecomprises aceton'e soluble cellulose acetate fibres and which have treated according .to the invention may have-the ir-somewhat scroopy butbroadly comprisess'preading a paste, emulsion or a thickened solution of the agent over the back'of the fabric; e. g., by means of a roller or spreading knife, removingthe dispersion medium or solvent. and, if necessary, heating or otherwise :treating the filling agent to increase its waterresistance and to reduce any residual tackiness. For example, .a thermo-setting synthetic resin may be -applied from solution or dispersion in an organic solvent while in the partially condensed condition, and the treated fabric may be sub- Jected tov heat in order to convert the resininto the thermoset insoluble state. [Again, the backing of a fabric may be impregnated with asolutionof a monomeric or'partially polymeri'sed derivative of vinyl alcohol, acrylic acid or methacrylic acid,-

-andthe fabric. then subjected to treatmentwhich- I will convertthe monomer orpartial polymer to Y a highly polymerised condition in which it-is resistant to water.

Plasticisers, pigments, and othersubstanceei 7 may be incorporated in the pastesor solutions with aview to modifying the flexibility; colour. or other characteristics of the-products- The backfilling composition may have the same colour as 7 that of the pile, or a different one.

While the filling agent is in. general applied after the fabflehas been treated witha boiling aqueousmedium according to the process .de-

; componentof the composition by thetreatment. lfabrics produced according to the invention are suitable for a number ofpurposes, such-forexhandle reduced, and maybe givena yellowish appearance, a reduced 'lustreand a somewhat "scribed aboveyihmay be applied. before suchtreatm ent, provided that the agent or another is not adversely ample as linings, fancy fabrics, rugs; carpets-and I in substitution for lambs wool, e. g., as shuttle linings and roller clearers. Their suitability for the various purposes will of course be affected by the filament denier of the pile as well as by its length. For example, pile of filament denier greater than has a somewhat rough handle, but is very resistant to crushing, and proves suitable for linings, e. g., for linings for heavy coats to be worn in cold climates; with pile filament deniers varying from 3 to 7 the fabrics are suitable for dress fabrics and outer-wear fabrics generally; while the finest deniers, e. g 1 or 2, give very soft surfaces, and fabrics having pile of such deniers may be employed for lining oxygen and 'other masks which are required to fit the face -tightly. Pile'fabrics treated according to the present invention may be employed for heat insulating purposes, particularly when two or more fabrics are superimposed.

of 2/120s cotton yarn (136 ends per inch), a pile warp of 170 denier yarns of 26 cellulose acetate filaments of fiat cross-section having a twist of 0.5 turn per inch (68 ends per inch) and a ground weft of '70s cotton (90 picks per inch), the pile length being inch. The fabv ric is boiled for 4 hours in an aqueous bath containing 2 grams of soap per litre, and is then dried and subjected to fan beating. The fabric possesses a soft pile finish with a slightlygranular appearance, the pile strongly resisting crushing.

. Example 2 'A' pile fabric is produced having a ground Warp of 2/70s cotton yarn (136 ends per inch), a pile warp of 172 denieryarns of 26 cellulose acetate filaments of flat cross-section having a twist of 05 turn per inch (68 ends per inch), and a ground weft of 32s cotton (78 picks per inch), the pile length being 5 inch. This fabric is padded through an aqueous solution of 2.5 grams caustic soda per litre, expression being adjusted to 75% increase in weight, and is dried and t"en boiled for 2 hours in an aqueous bath containing 20 grams per litre of Glaubers salts. It is then dried, padded with a liquor containing 40 grams of octadecyl-oxymethyl pyridinium ch oride per litre and 8 grams of sodium acetate per litre, expression being adjusted to 80% increase in weight, stenter-dried at 80 C. and stoved for 2 minutes at 140 C. After washing and redrying the fabric is finally subjected to fan beating. It is then found to possess the appearance of lambs wool on the skin, and may, for

example, be employed in the production of gloves and in substitution for lambs wool in shuttle linings. In the-production of gloves from such a fabric. two sheets of fabric may. be placed back to back so that both the outside and the, inside of the glove present a pile surface.

Example 3 a mixture or 10 partsby weight of toluene, 10 parts by weight of alcohol and 66 parts by weight of tricresyl phosphate is mixed with200 parts by weight of the synthetic resin sold under the trade name Bedafin 2001; the resulting mixture is gradually added to 400 parts by weight of kaolin,

400 parts of the plasticiser sold under the trade name- Bedafin 285K is then stirred into this paste,

while grinding to produce a smooth paste.

followed by 70 parts by weight of water. A paste is thus produced which has an excellent consistency for back-filling and which has a white opaque appearance which is retained in the finished fabric. The Bedafin compounds referred to are marketed by the Imperial Chemical Indus-- tries Limited. a a

A pile fabric produced according to Example 1 or 2 is given two back-filling treatments with the paste on a mangle under conditions such that about 10-15% of the paste, based on the weight of the fabric, is applied thereto. The fabric is dried by passing over steam-heated rolls, and after stoving for about 2 minutes at 149 C. is found to be substantially windand water-proof. residual tackiness in the product may be reduced by the application of talc.

Example 4 A solution of 45 parts by weight of cellulose acetate in 135 parts by weight of acetone is thoroughly stirred into a paste of 150 parts by weight of kaolin and 175 parts by weight of (ii-(methyl glycol) phthalate. 60 parts of water is stirred into the resulting paste, and the composition so produced is applied to a pile fabric asdescribed 'in Example 3, in quantity about 13-20% based on the weight of the fabric. The fabric is dried by passing over steam-heated rolls. Theproductis highly windand water-proof. v

Example 5 A solution of 45 parts by weight of ethyl cellulose, having an ethoxy content of 4fi.5-8.5% and a viscosity of about 250 centipoises, in 60 parts by weight of methylated spirits and 60 parts by weight of solvent naphtha containing 45 parts by weight of castor oil is thoroughly mixed with a suspension of '75 parts of French chalk in 60 parts by weight of solvent naphtha. Three coatings of the resulting composition are applied to I the backing of a pile fabric, as described in Example '3, the fabric being dried by passing over steam-heated rolls.

Having described our invention what we desire to secure by Letters Patent is: I

1. Process for the production of effect fabrics resembling animal pelts in appearance, which 7 .duce at most a slight superficial saponification of the pile, and thereafter subjecting the fabric to the crinkling action of a boiling aqueous medium.

3. Process for the production of effect fabrics having a granulated appearance, which comprises subjecting a pile fabric, of which the pile comprises fiat filaments of a cellulose ester of an organic acid and'of which the pile length before treatment is at least about inch, to the crinkling action of a boiling aqueous medium.

v v I -4. Process for the production of windor waterproof eifect fabrics, whichcomprises impregnating the backing. of a pile fabric, of which the pile comprises flat filaments of a cellulose ester of an organic acid, with a hydrophobe coating material, .and subjecting the fabric to the crinkling action of a boiling aqueous medium.

i 5. Process for the production of windor waterproof effect fabrics, which comprises subjecting a pile fabric, of which the pile comprises fiat filaments'of a cellulose ester of an organic acid, to the crinkling action of a boiling aqueous medium, and thereafter impregnating the backing ofthe said pile fabric with a synthetic hydrophone coating material.

, 6. Process fdr the production of windor water-proof effect fabrics, which comprises impreghating the backing of a 'pile fabric, of which the pile comprises flat filaments of a cellulose ester of an organic acid, with a synthetic hydrophobe coating material, and thereaftersubjecting the fabric to the crinkling action of a boiling aqueous m m- 7. Process for the production of efi'ect fabrics resembling animal pelts in appearance,- which comprises subjecting a pile fabric, of which the pile comprises flat filaments of a cellulose ace tate, to the crinkling action of a boiling aqueous resembling animal pelts in appearance, which comprises passing a pile fabric, of which the pile comprises fiat fllaments'of-a cellulose acetate, through a caustic soda bath, and then subjectas'raoes i medium containing a wetting agent, for at least 2 hours, while the fabric is substantially free from tension, any saponification of the pile of the fab-- u ric due to said caustic soda treatment being at most slight and superficial.

13. Process for the production of effect fabrics resembling animal pelts in appearance, which least 2 hours, while the fabric is substantially free from tension.

14. Process for the production of effect fabrics resembling animal pelts in appearance, which comprises passing a pile fabric, of which the pile comprises fiat filaments of a cellulose acetate,

through a caustic soda bath, and then subjecting it to the crinkling action of a boiling aqueous medium containing an agent adapted to counteract the delustering tendency of themedium, for at least 2 hours, while the fabric is substantially free from tension, any saponification of the pile.

of the fabric due to said caustic soda treatment being at most slight and superficial.

15. Process for the production of effect fabrics 4 resembling animal pelts in appearance, which comprises passing a pile fabric, of which the pile comprises fiat filaments of a cellulose acetate, to the crinkling action of a boiling aqu for at least 2 hours, while the fabric is substantially free from tension.

16. .Process according-to claim 7, wherein the treatment with the boiling aqueous medium is i applied only to selected areas of the fabric. 17. Process according to claim- 9, wherein the treatment with the boiling aqueous medium is applied only to selected areas of the fabric.

18. Process for the production of effect fabrics y-resemblingv animal pelts in appearance, which ing' it to the crinkling action of a boiling aqueous medium," for at least 2 hours, while the fabric is substantially free from tension, any saponiflcation of the pile of the fabric due to said caustic m treatment being at most. slight and superv "10. Processfor the production of eflect'fabrics' r in nima D ta in appearance, which aqueous medium for at least 2 hours, while the fabric is substantially free/ from tension, any saponification of the pile of the fabric resulting from'said caustic soda treatment being at most slight and superficial;

1 11. Process for the production or eifect fabrics comprises subjecting a pile fabric, of. which the pile comprises-fiat filaments of a cellulose acetate, to the crinkling action of a boiling aqueous medium forat least 2 hours while the fabric is substantially free fromv tension and thereafter subjecting the fabric to a further treatment with an'adipylating agent. I

19'. Process for the production of efiect fabrics resembling animal pelts in appearance, which comprises subjecting a pile fabric, of which the pile comprises flat filaments of a cellulose acetate, to the crinkli'ng action of a boiling aqueous medium for at least'2 'hours while the fabric is substantially free from tension and thereafter sub' le'cting the fabric to a further treatment with resembling animal pelts in appearance, which comprises passing a pile fabric, of which the pile comprises-fiat filaments; of a cellulose acetate, to

the crinkling action-ofa boiling aqueous medium a wetting agent, for at least. 2 hours,

1 12. Process for the'productio'n of efl'ectfabrics .hile the fabric issubstantially free from ten-- resembling animal pelts in appearance, which* comprlsespassinga pile fabric, .o'fwhich the pile comprisesifiatfilaments-of a cellulose acetate, through a caustic sodafbath, and then subjecting'it to actionof aboiling aqueous 'a dilute aqueous solution of an etherifying agent. 00

. resembling animal pelts in appearance, which (comprises subjecting a pile fabric, of which-the pile comprisesflat filaments of a cellulose acetate,

20. Process for the production of effect fabrics to the crinkling action of a boiling aqueous medium for at least 2 hours while the fabric is substantially free from tension and thereafter treatin the fabric with an aqueous solution of the .pyridinium compound of octadecyl-oxy-methyl chloride, drying the fabric, and subsequently bak- .ingit at about C. I

21. Process for the production of windor;

water-proof 'ect fabrics, which comprises impresnating the backing of a pile fabric, of which the pile comprises fiat filaments of a cellulose derivative, witha synthetic resin, and subjecting. 1

us medium 1 containing a small proportion of Glaubers salts,

. '22; Process according toclaim 21, wherein the synthetic resin is produced in the backing by polymerization of a substance selectedfrom the group polymersthereof.

23. Process for the production of windor water-proof effect fabrics,-which comprises impregnating the backing of a pile fabric, of which the pile comprises fiat filaments of a cellulose dei Y v t assumes the fabric to'the crinkling action or a pmgnating,the'backlng'of a pilefab c, of'which 'the'ipile comprises flat'fi'ianients o a cellulose derivative, with an ethyl cellulose. and subie'ctins rivative, with an inter-polymer, of a diene and another polymerizable unsaturated compound, and subjecting the fabric to the crinkling action of a boiling aqueous medium. I

24. Process for the production of windor water-proof efiect fabrics, which comprises impregnating the backing of a pile fabric, of which the pile comprises flat filaments of a cellulose "j derivative, with a cellulose derivative, and subi iectingthev fabric to the'crinlrling'action of a boiling aqueous medium.

25. Process for the production of windor the fabric to the crin kling aqueousmedium.

'25, Meet fabrics wile-meetin animalopelts in appearance and which comprise a. pile fabric; of which the pile comprises crinkled flat filaments of a cellulose ester of an organic acid. 1

27. Effect fabrics having :a granulated appearance and which comprise a pile fabric of which the Pile comprises crinkled flat filaments or a cellulose ester of an organic acid, the uncrinkled length of the pile being at least about inch.

28. Effect fabrics which resemble animal pelts inappearanc'e and which-comprise a pile fabric, of which the pile comprises crinkled fiat filaments of a cellulose ester of an organic acid, having a backing impregnated with a hydrophobe coating material. a g

,WILLIAM'IVAN TAYLOR. JAMES FREDERICK IEVERS. o

action of a boiling 

